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Installing a Cobblewood Floor

Birger Juell visits the home to supervise instalation of this unique floor. Use 3/8 or 1/2 inch thickness of wood. Type of wood is user preference but it should be as dry as possible. The wood tiles can be just about any size or shape as long as they are not too large or warping will occur. The grout for the cobblewood flooring is composed of sawdust from the wood mixed with a fast-drying oil-based sealer in a ratio of 2 parts sawdust to 1 part sealer add any stain to grout to your liking.Insure you have a standard sub-floor. First glue floor down, use regular tile mastic as an adhesive. rubber based instead of Water based is best. Let set for two days... Then grout, Pour the grout on the floor push it into the cracks using a rubber trowel or your hands. Trowel in the grout. Squeegee off the excess. Steel wool the face of the wood tiles to remove any remaining excess grout that could dry to the top of the bricks. Let it sit over night and then apply another coat of oil-based sealer the next day. Let set for one day. Then do final coat of varnish, stain etc. Maintain like any wood floor. Oil it every 2 years using wood floor oil. Varnish once a year. Buff once a month.
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Installing a Cobblewood Floor

  computer-generated transcript - may not be 100% accurate

" Okay right now we're gonna talk with Birger Juell; and Birger you pretty much developed this type of flooring right?"

" That's right."

" Yeah, it's just a beautiful idea."

" Well, a man came to me with some all lumber out of an old factory."

" Donnelley [unk] in fact. He said I got millions of these little squares"

" They have 3 x 4 x 6. And we used in a machine shop, so they paint the floors in the machine shop----"

" Shop."

" to absorb the shock of the----"

" to----"

" running [unk]"

" and the truck and everything with [unk] very durable."

" Yeah."

" So, and of course it would block and terribly he said "Well, see what you can do". So, I took it home----"

" and I split it in 2, and look to that this great grain----"

" Yeah"

" And I said, wow! It has the possibility."

" Sure."

" So, I put together a sample and put it in my show room"

" And people liked it."

" I sold a job."

" So, all you do is you take old beams from barns now?"

" Yes, we take, we buy our barns----"

" Yeah."

" and get beams, slice them to whatever dimension we want."

" Right."

" And then hand bevel and install them."

" Fantastic."

" All you do is put a little beveled edge on it----"

" Yes."

" and you get the feeling of old cobblestone"

" The cobblestone."

" Kind of, yeah."

" That's where the cover wood comes in"

" Exactly, let's talk with Chuck about the installation process. Hi Chuck."

" Hi!"

" You've already, well, you've already put some down what---- well, take us back. What's the first consideration here?"

" The first thing to do is map out the room. Start right down the center of the room----"

" with a chalk line squared up both ways. So, this is a 12-foot wide room when you went to the 6 squared point."

" 5 to 6 feet. What about the subfloor that we gave you was it good enough?"

" Yeah, this is a good shape and this would be a pretty sound 3/4-inch plywood subfloor----"

" Right"

" all that can be sold and installed over time for it also."

" Yes."

" Now, the next move is just to keep putting down snap lines to keep it fairly uniform."

" Do you do it in sections put it at times or what?"

" I do about 5 rows at a time. That's what I've done here. I've set up here for 5 rows."

" Alright, and you have to put down a chalk line for each row or----"

" Right, just to keep it uniformed. We got it marked out already."

" So, here, I'll hold this way."

" Okay."

" What a big low isn't it?"

" Get it?-Nice."

" Okay, so then, you're actually going in sections 5 across. What about the mastic that you do?"

" Mastics that is rubber-based. I don't wanna use a water-based mastic with this product."

" Why not?"

" It'll cut the wood."

" Ah!"

" I've got about and a quarter inch trial. [unk] fairly thin. Alright, this is the line"

" I like the look of that mastic it's nice and gluey."

" I usually start on the outside just keep it fairly uniform. Press them into place and instill into the middle."

" And you're going absolutely randomly right? You're not trying to match one tile to the other?"

" No, I try to keep it as good as random as possible."

" I noticed that one has a big knot. Do you have to worry about knot popping out?"

" Usually the knot if they're gonna pop out, they've already done so."

" [unk] the spacing about even, little plus or minus trying to keep the lines fairly uniform."

" What's the nature of the mastic? How long will it be soft like that before you can go to your next step?"

" It takes a full 2 days before you can go to the grounding process before you can really walk on the floor."

" Okay."

" We'll do the last walls and the wall cuts I'll put a piece of plywood down work on top of that."

" This section of the kitchen floors has had 2 days to set up. This mastic has all dried. Now, chuck what is this process?"

" controlling in the grout."

" And what is the grout? It's not like what you would use with ceramic tile, it's something else."

" Well, maybe it's sawdust----"

" from this---- from the wood."

" Yeah."

" mixed with the fast-drying oil-based sealer."

" What's the ratio of the mixed?"

" Two parts sawdust about one parts of liquid"

" Great looking stuff."

" And you just dump it down."

" Just put it right on the floor push it into the cracks."

" Using a rubber tool there."

" Right, you can do it with your hand do it with a trowel, take out the excess or some form of [unk]."

" Isn't beautiful though, the grain of the wood?"

" And a trial of---- seal all the face, so take that out the excess----"

" so it doesn't dry on the top of the bricks."

" Yeah. And then how long does this have to sit before you can walk on it or is there another steps?"

" Overnight, the next day you would come back and put on another coat of oil based-sealer."

" Now Birger, how much maintenance is required to the floor like this?"

" Really very little. Apply oil a couple of times every 2 years, wax it once a year, and buff it once a month [unk]."

" So, you buff it regularly?"

" Yes."

" And imagine this is the kind of floor that really takes on a beautiful pristine."

" Beautifully."

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